Method and means for assembling and packaging reflector-type lamps



April 26, 1966 M. LIBERMAN 3,247,954 METHOD AND MEANS FOR ASSEMBLING ANDPACKAGING REFLECTOR-TYPE LAMPS Filed Aug. 20, 1963 3 Sheets-Sheet 1 INVEN TOR.

April 26, 1966 M. LIBERMAN' 3,24 METHOD AND MEANS FOR ASSEMBLING ANDPACKAGING REFLECTOR-TYPE LAMPS Filed Aug. 20, 1963 3 Sheets-Sheet 2 1 NVEN TOR. /l //4 ra/v Z/BE/PM/FN (ET tr April 26, 1966 M. LIBERMAN3,247,954

METHOD AND MEANS FOR ASSEMBLING AND PACKAGING REFLECTOR-TYPE LAMPS FiledAug. 20, 1963 3 Sheets-Sheet 5 INVENTOR. M 7011/ Z/SEE/VIH ATTGR;

United States Patent 3,247,954 METHUD AND MEANS FOR ASSEMBLING ANDPACKAGING REFLECTUR-TWE LAMPS Milton Liherman, 65 flewaue Road, EastRockaway, NX. Fitted Aug. 20, 1963, Ser. No. 303,268 (Ilaims. (Cl.lite-46) This invention relates to the assembly and packaging ofreflector-type electric lamps, and more specifically, to a novel andimproved method for manufacturing and packaging reflector-type electriclamps for storage and shipment.

The manufacture and packaging of electric incandescent lamps havingexternal reflectors secured thereto has presented serious difficulties,particularly in instances where in the external reflector secured to thelamp is fabricated of a very thin fragile material. Heretofore, thereflectors were cemented to the lamps by a process requiring theutilization of jigs arranged to receive a number of reflectors. When thereflectors were inserted in the jigs, cement was applied at the pointsof contact with the lamp and then the lamp was inserted and held inalignment with the reflector. The reflectors and lamps remained in thejig until the cement hardened, whereupon each assembled lamp andreflector was then removed and suitably packaged. The adhesive found tobe most useful for cementing a reflector to a lamp is an air dryingadhesive that requires from twelve to twenty-four, hours to set. It isevident, therefore, that with the utilization of such ad hesives, massproduction of a lamp and reflector combination requires an exceedinglylarge number of jigs and a substantial amount of space for the storageof the jigs with assembled lamps and reflectors. Furthermore, a separateoperation is required for the removal of the lamps and reflectors fromthe jigs and insertion in protective packages. The procedure isrelatively expensive and results in the addition of material cost to thefinished product.

This invention overcomes the difiiculties heretofore encountered withknown procedures for fabrication and packaging of lamps with externalreflectors secured thereto and provides an improved method ofmanufacturing and packaging which greatly reduces the cost of thefinished article, simplifies assembly, and avoids the need for storagespace of a large quantity of lamps to permit the cement to set.

Another object of the invention resides in the provision of a novel andimproved method for assembling external reflectors to incandescentlamps.

Still another object of the invention resides in the provision of anovel and improved package for incandescent lamps having externalreflectors and wherein the reflector and lamp are assembled in thepackage itself and are immediately ready for shipment.

Still another object of the invention resides in a novel and improvedpackage for incandescent lamps having external reflectors securedthereto.

A still further object of the invention resides in the provision of anovel and improved shipping and dispensing carton for packaged electriclamps having external reflectors secured thereto.

The above and other objects of the invention will become more apparentfrom the following description and accompanying drawings forming part ofthis application.

In the drawings:

FIGURE 1 is an exploded perspective view of a lamp and externalreflector in position for assembly within a protective package inaccordance with the invention.

FIGURE 2 is a perspective view of an assembled lamp and reflector withinthe package in accordance with the invention.

FIGURE 3 is a cross-sectional view of the lamp package in accordancewith the invention and placed in a support for receipt of a lampreflector.

FIGURE 4 is a cross sectional view of the lamp package of FIGURE 1 witha reflector seated therein.

FIGURE 5 is a cross-sectional view similar to FIG- URE 4 with the lampinserted and cemented to the reflector.

FIGURE 6 is a cross-sectional view similar to FIGURE 5 with a retainingcover secured to the package and retaining the lamp and reflector inposition therein.

FIGURE 7 is a cross-sectional view of a fragmentary portion of FIGURE 6but with a modified retaining'cover.

FIGURE 8 is a bottom view of the lamp package showing a modified form ofthe opening which receives the lamp neck.

FIGURE 9 is a fragmentary cross-sectional view of a carton for receivingand holding a plurality of packaged lamps as shown in FIGURE 6.

FIGURE 10 is a cross-sectional view of a modified form of lamp packagein accordance with the invention.

FIGURE 11 is a cross-sectional view of FIGURE 10 taken along the line11-I1 thereof.

FIGURE 12 is a cross-sectional view of a modified carton for containingpackaged lamps in accordance with the invention.

FIGURE 13 is a perspective view of a portion of a packing element forholding packaged lamps within the carton shown in FIGURE 12.

As pointed out above, the invention concerns the provision of animproved package which not only is adapted to receive and protect anincandescent lamp with an external reflector cemented thereto duringshipment, but

also provides improved means for assembling a lamp and reflector andretaining the two in position one relative to the other so that theassembled lamp and reflector within the improved package can beimmediately inserted into shipping cartons and shipped thus avoiding thenormal storage time to permit the adhesive to set. With this invention,the lamps are so firmly held in contact with the associated reflectorthat the stresses to which the lamp and reflector may be subjectedduring shipment will not adversely affect the resultant article, and thecement will set and firmly adhere the lamp to the reflector during thecourse of shipment.

The improved lamp package in accordance with the invention is shown inFIGURES l and 2 and is generallytom 13. The bottom 13 includes anopening 14 which isadapted to snugly receive the neck 15 of the lamp 16.The upper portion 17 of the body or shell Ill is integrally formed withthe portion 12 and is flared sharply outwardly andupwardly andterminates in a flanged or beaded edge 18. The lamp reflector 19, whichmay be formed of any suitable material having an internal reflectivesurface, has a curved annular portion 2% which is integrally joinedabout the edge 21 to a forwardly flared section 22 terminating in abeaded or rolled edge 23.

The portion 20 of the reflector has an enlarged opening 24 through whichthe neck 15 of the lamp extends and a plurality of tabs 25 carried aboutthe edge of the opening 24 are utilized to cement the reflector to thelamp 16. The lamp 16 and reflector 19 are held in position within thebody of the package 10 by a cover 26 which has a reverse flange 27 forengaging the flange 18 on the package and an embossed central portion 28which engages the bulbous portion 29 of the lamp 16 and cooperates withthe opening 14 to hold the lamp in alignment within the package.

The package in accordance with the invention is designed to receive areflector of specific size and configuration, and for this purpose thepackage or shell 11 is arranged so that its internal diameter at theline of joinder 11 of the sections 12 and 17 is approximately equal tothe outside diameter of the portion of the reflector at the point Whereit joins the flared reflector portion 22. Furthermore, the portion 17 ofthe package body or shell should preferably extend above the front edgeof the reflector 19 when the latter is inserted therein. In this way,the body will hold and align the reflector 19 within the body and uponinsertion of the lamp 16, the cooperation of the cover with the opening14 in the body will hold the lamp in precise and firm alignment with thereflector.

The assembly of the lamp and reflector within the package is illustratedmore clearly in FIGURES 3 through 6. The shell 11 of the package inaccordance with the invention is inserted in any suitable jig such asthe jig 38 which has a central opening 31 adapted to receive the bodyportion 12 with the body portion 17 flaring outwardly and upwardly fromthe top surface 32 of the jig 30. When the shell 11 is in place withinthe jig as shown in FIG- URE 3, the reflector 19 is inserted within thebody as shown in FIGURE 4. It will be observed that the junction 21 ofthe upper and lower sections of the reflector is in line with thejunction 11 of the upper and lower sections of the shell 11, and bothjunctions are approximately in line with the top surface 32 of the jig30. It will also be observed that the top edge 23 of the reflector isbelow the top edge 18 of the body 11. With this arrangement, thereflector is firmly seated within the body 11 of the package and is inprecise alignment therewith, that is, the reflector and the package bodyare substantially concentric.

When the reflector is in place within the body as shown .in FIGURE 4, asuitable adhesive is applied to the edges 25 of the tabs or supports 25and the lamp 16 is then placed in position as shown in FIGURE 5. It willbe observed that the top of the bulbous portion 29 of the lamp extendsslightly above the edge 18 of the package body and the neck 15 of thelamp extends through the opening 14 in the bottom 13 of the packagebody. With this arrangement, the tabs 25 on the reflector 19 and theopening 14 accurately align the lamp with the reflector and the adhesive33, applied to the edges 25 of the tabs, functions to bond the tabs tothe bulbous portion 29 of the lamp. The adhesive is preferably an airdrying adhesive, though it is evident that any suitable type of adhesivemay be employed, as, for instance, epoxy resins and the like.

When the lamp ,16 is in position as shown in FIGURE 5, the cover 26 isapplied as shown in FIGURE 6. The reverse flange 27 on the cover 26interlocks with the flange 18 on the body or shell 11, and it urges theembossed portion 28 of the cover into firm engagement with the bulbousportion 29 of the lamp. In this way, the lamp is axially aligned withthe body 11 of the package 10 and since the reflector 19 is also alignedwith the body 11, the lamp will therefore be precisely positioned withrespect to the reflector. The cover 26 places a slight stress on thelamp urging it firmly against the tabs 25 so that any jarring of theassembly as shown in FIGURE 6 will not displace the lamp relative to thereflector. As a result, the packaged reflector lamp as shown in FIG- URE6 is ready for immediate shipment, even though the cement 23 has notactually set. Furthermore, with normal distribution processes, the timerequired for an article to be transported from the point of manufactureto the point of use usually involves at the minimum several days, withthe result that an air drying resin requiring twelve to twenty-fourhours will set by the time the lamp and reflector are removed from thepackage for use.

In the form of the invention described above, the bottom opening 14 inthe shell 11 was an annular opening which snugly received the neck 15 ofthe lamp 16. If desired, an opening such as the opening 14' as shown inFIGURE 8 may be employed. With this arrangement, the tolerance of theopening is not critical since the inwardly extending salient'portions ofthe opening can be easily deflected upon insertion of the lamp and atthe same time will effect precise alignment of the lamp within the body11.

While packaged lamps in accordance with the invention may be housed inany suitable container for shipping, one form of container is shown inFIGURE 9 and is denoted generally by the numeral 34. The container whichis shown in fragmentary form includes a top wall 35, a bottom wall 36and internal liners 37 and 38. The liners 37 and 38 are each providedwith a plurality of spaced triangularly shaped projections 39 which aredisposed in parallel relationship transversely of the carton. Theprojections 39 on the liner 37 are spaced to slidably receive and holdthe enlarged portions of the packages 10 with the bottom ends or basesof the lamps in spaced relationship to the projections 39 on theopposing liner 38. The liner 38 is similarly arranged with spacedprojections or ribs 39 to receive packages 10 in an inverted position asclearly illustrated. With this arrangement, the packages are nestedwithin the container and are securely held in position so that thecontainer can be stored in any position. If desired, the container 34can also be arranged so that lamps can be dispensed directly from thecontainer without necessitating the removal and storage of theindividual lamp shelves.

While the invention has been described in connection with a lamp of asingle size, as shown for instance in FIGURES 1 through 6, it ispossible to utilize the invention with a lamp 16 of somewhat smallerconfiguration, provided that the lamp when positioned in the reflector19 has its filament properly aligned therewith. In the event the lamp isof smaller size, a modified cover can be utilized with the package 10 inorder to secure the lamp firmly in position against the reflector 19.This form of the invention is shown in FIGURE 7, in which the cover isdenoted by the numeral 26. The central portion of the cover is providedwith a cylindrical element 40 carrying a curved wall portion 41 whichcontacts the smaller lamp 16. The curved wall portion functions in thesame manner as the embossment 28 on the cover 26, except that it isdisplaced inwardly in order to compensate for the lamp size. A coverstructure such as shown in FIG- URE 7 may be readily fabricated by anysuitable embossing or other forming process.

The lamp package shown in FIGURE 10 is substantially identical to thepackage shown in previous figures, and corresponding elements of theembodiments of the invention shown in FIGURES 1 and 10 are denoted bylike numerals with the numerals of FIGURE 10 primed. The

i base 13' of the package 10' shown in FIGURE 10 is provided with acentral opening 43 to receive the lamp neck. The opening has a pluralityof V-shaped cutouts 44 about the edge with the cutouts spaced one fromthe other to form short arcuate sections 45 therebetween for alignmentof the lamp neck and to permit the portions 45 to be slight- 1ydeflected and accommodate variations in diameter of the lamp neck. Therim 46 of the flared portion 17 is reversely formed to provide aninwardly extending headlike element 47 terminating in an outwardlyextending flange 48. The cover 49 is provided wtih an annular depression50 having a diameter which will receive the bulbous portion of the lampand align it with the reflector 19. The periphery of the cover isprovided with an inwardly formed peripheral recess 51 terminating in anoutwardly extending flange 52. The recess 51 receives the inwardlyextending bead-like portion 47 on the flared portion 17' of the shelland locks the cover in place with the flanges 48 and 52 in overlyingrelationship and with the central portion of the cover engaging thebulbous portion of the lamp.

FIGURES 12 and 13 show a modified carton arrangement for receiving aplurality of packaged lamps or '10 as the case may be. The carton,generally denoted by the numeral 53, -is of conventional rectangularconstruction having a pair of spaced walls 54 and 55 for the receptionof packaged lamps 10 or 10' as the case may be. The packaged lamps aresupported within the container 53 by a plurality of elongatedrectangular elements 56 having a top wall 57 with spaced openings 58 forthe reception of the lamp bases. The side walls 5-9 and 60 includearcuate cutouts 61 aligned with the openings 58 and preferablyterminating a short distance above the rear Wall 62 to provide elongatedspacer members 63. When packing a plurality of lamps within the carton53, a packing strip 56 may be first placed against one wall 54 in acorner of the carton. Lamps are then placed in the openings 58 of asecond packing strip 56, and the strip together with the lamps is thenpositioned in the cart-on with the rims of the lamp packages engagingthe openings 61 in the first strip. This procedure is then repeated,with each group of lamps being reversed within the carton until thecarton has been completely filled. If desired, suitable additionalspacing means may be provided at the ends of the carton to prevent thelamps from shifting within the carton.

The packages 10 and 10, together with the cover, may of course befabricated of any suitable material, though it has been found thatplastic materials are most suitable,

since the material can be readily formed into any desired shape orconfiguration and can be made exceedingly thin and light in weight. Itis possible, of course, :to fabricate the package of other materials,such as metals and the like.

While only certain embodiments of the invention have been illustratedand described, it is evident that alterations, modifications and changesmay be made without departing from the true scope and spirit thereof asdefined by the appended claims.

What is claimed is:

l. A package for an electric lamp having an envelope including a bulbousportion, a neck and a base secured to the neck and a reflectorsurrounding at least a portion of v the bulbous portion with at leastpart of the neck exposed,

comprising a double open-ended shell having an opening in one end forreceipt of said reflector and an opening in the other end for snuglyengaging the neck of said envelope, said shell having a configurationcorresponding at least in part to said reflector and engaging at least aportion of said reflector t-o firmly align it therein with the neck ofthe lamp envelope extending through the opening in said other end of theshell, and a cover closing the opening in said one end of the shell,said cover including means engaging the bulbous portion of said envelopeto retain the lamp envelope in alignment with said reflector and saidshell.

2. A package for an electric lamp according to claim 1 wherein saidreflector is formed of two annular portions of different curvaturejoined one to the other and forming an annular concavity and whereinsaid shell has an inwardly extending annular shoulder snugly engagingsaid annular concavity in said reflector.

6. A package for an electric lamp according to claim 1 wherein saidcover includes a central embossed portion having a curvaturecorresponding generally to at least part of the bulbous portion of saidenvelope.

4. The method of assembling and packaging an electric lamp withanannular reflector cemented thereto comprising the steps of placing areflector having tabs to be cemented to a lamp within a packaging shellhaving reflector and lamp receiving and aligning means, applying anadhesive to said tabs, placing a lamp in said reflector and inengagement with said tabs and lamp aligning means and then attaching acover to said shell, said cover engaging said lamp to urge it into firmcontact with said tabs and fixedly align said lamp and said reflectorwithin said shell.

5. The method of assembling and packaging an electric lamp with anannular reflector wherein said lamp has an envelope including a bulbousportion, a neck extending from the bulbous portion and a base secured tosaid neck, and said reflector surrounds at least part of the bulbousportion with at least part of the neck exposed and includes tabs adaptedto be cemented to said envelope, comprising the steps of forming anannular double open-ended shell having a portion adjoining one endthereof conforming generally to at least part of said reflector andhaving reflector receiving and aligning means and a lamp neck receivingopening at the other end thereof, inserting said refiector in said oneend of said shell and in engagement with said reflector aligning means,applying an adhesive to said reflect-or tabs, inserting the neck portionof a lamp through said reflector and the lamp neck receiving openinguntil said lamp envelope engages said tabs and then enclosing said oneend of said shell to hold said lamp in alignment with said reflector andshell and in firm engagement with said tabs.

6. The method of assembling a lamp and surrounding reflector adapted tobe cemented to the lamp and of packaging the assembled reflectorcomprising the steps of placing a lamp and the surrounding reflectorwith an adhesive disposed therebetween within a lamp and reflectorreceiving and aligning package and then securing said lamp and reflectorin said package for shipment, said package protecting said assembly andholding said lamp and reflector in firm engagement and alignment whilesaid adhesive sets and during shipment thereof.

'7. A jig and package for lamp and reflector assemblies wherein saidlamp includes an envelope having neck and bulbous portions and whereinsaid reflector has tabs adapted to be cemented to the envelope andsurrounds at least part of the bulbous portion with at least part of theneck exposed, comprising a shell having an enlarged refiector receivingopening in one end thereof and a small lamp neck receiving opening inthe other end thereof, annular means within said shell for snuglyreceiving and aligning said reflector, said reflector having lampattaching and aligning means whereby insertion of the lamp with the neckextending through said small opening and with the lamp engaging saidattaching means automatically aligns the bulb and reflect-or within theshell and cover means having a central lamp engaging embossment closingsaid enlarged opening and urging said lamp in engagement with attachingmeans, said lamp being held in alignmerit with the reflector by saidembossment and neck receiving opening.

8. A jig and package according to claim 7 wherein said reflector isformed with a shallow annular curved portion and an outwardly flaredsection joined one to the other and forming an annular trough-likegroove, and said annular aligning means comprises an inwardly extendingshoulder for engaging said annular groove in said reflector.

*9. A jig and package according to claim 8 wherein said shell is formedof a lower cup-like section having a generally cylindrical rim taperingdownwardly and inwardly toward the bottom, the latter having the neckreceiving opening therein, and an upwardly extending flared portionjoined to the lower section and curving sharply outwardly therefrom toform said reflector receiving and aligning means, said upwardly flaredportion having a larger diameter than the flared portion of saidreflector.

10. A jig and package according to claim 8 wherein said shell is formedof a lower cup-like section having a. generally cylindrical rim taperingdownwardly and inwardly toward the bottom, the latter having said neckreceiving opening therein, an upwardly extending flared portion joinedto the lower section and curving sharply outwardly therefrom to formsaid reflector receiving and aligning means, said upwardly flaredportion having a larger diameter than the flared portion of saidreflector, a peripheral cover-engaging bead about the outer edge of 7 3the flared portion of said shell and wherein said cover ,77 12/ 1956Williams 20665 closes the last said flared portion and engages saidbead. 2,806,594 9/ v1957 Muller et a1 206-65 3,136,413 6/1964 Hall 20646References Cited by the Examiner FOREIGN PATENTS UNITED STATES PATENTS 560,596 4/1954 France. 573,333 12/1896 Krimmel. (1st add. of 1,015,065)2,03 1,851 2/1936 Plunkett 2061 2 102 3 .12 193 Conner. v LOUIS G.MANCENE, Primary Examiner.

2,545,762 4/1951 Brown 20646 10 THER-ON E. CONDON, Examiner.

1.A PACKAGE FOR AN ELECTRIC LAMP HAVING AN ENVELOPE INCLUDING A BULBOUSPORTION, A NECK AND A BASE SECURED TO THE NECK AND A REFLECTORSURROUNDING AT LEAST A PORTION OF THE BULBOUS PORTION WITH AT LEAST PARTOF THE NECK EXPOSED, COMPRISING A DOUBLE OPEN-ENDED SHELL HAVING ANOPENING IN ONE END FOR RECEIPT OF SAID REFLECTOR AND AN OPENING IN THEOTHER END FOR SNUGLY ENGAGING THE NECK OF SAID ENVELOPE, SAID SHELLHAVING A CONFIGURATION CORRESPONDING AT LEAST IN PART TO SAID REFLECTORAND ENGAGING AT LEAST A PORTION OF SAID REFLECTOR TO FIRMLY ALIGN ITTHEREIN WITH THE NECK OF THE LAMP ENVELOPE EXTENDING THROUGH THE OPENINGIN SAID OTHER END OF THE SHELL, AND A COVER CLOSING THE OPENING IN SAIDONE END OF THE SHELL, SAID COVER INCLUDING MEANS ENGAGING THE BULBOUSPORTION OF SAID ENVELOPE TO RETAIN THE LAMP ENVELOPE IN ALIGNMENT WITHSAID REFLECTOR AND SAID SHELL.